Additive Intelligence 4.0: Speaker interviews

Hello, Mélanie Despeisse, Associate Professor in Sustainable Digitalized Production at Chalmers University of Technology, and speaker at the Additive Intelligence 4.0 conference in March.

You are part of a panel discussion on the topic: “Additive manufacturing contributes to sustainability - myth or reality?” How will you tackle the subject?

"I will talk about how additive manufacturing could be a powerful driver for circular and eco-efficient manufacturing. Right now, we cannot afford to have any technologies that do not contribute to sustainable development, and I strongly believe that additive manufacturing is especially well positioned to propel us in a sustainable direction. But it’s not going to happen by default."

What do you hope to convey to the audience?

"The fact that we need to be very intentional, very purposeful, in how we design, develop, and implement technologies. And systematically check that these processes align with sustainability principles. Failure to do so is likely to result in undesirable or unintended consequences that are often unsustainable. For me, it is imperative to make sustainability a non-negotiable aspect in the development and implementation of technologies. If a technology does not contribute to sustainability, we need to revisit the drawing board, as there is a design flaw somewhere that needs addressing."

In your opinion, what are the potential long-term benefits of additive manufacturing?

"I believe there's potential for additive manufacturing to become a mainstream business practice for very eco-efficient and circular manufacturing, precisely where and when it's needed. This shift could significantly contribute to more sustainable consumption patterns. While our focus is on production, it's important to recognize that how we produce things also influences how we consume them."

You are of course also a conference attendee, is there any session that you are particularly excited about?

"I am really curious about the session focusing on simulation and artificial intelligence, particularly as I'm not directly involved in AI-related work. I'm intrigued by the potential impact these elements can have on advancing the sustainability of additive manufacturing. While I have colleagues who specialize in machine learning for applications such as smart maintenance or predictive modelling, I haven't seen it as much applied in the context of eco-efficient additive manufacturing. Consequently, I'm eager to understand how these innovative technologies can enhance and complement the existing capabilities of additive manufacturing for environmental sustainability."

Hello, Dirk Herzog, Senior Engineer at the Institute for Industrialization of Smart Materials, Hamburg University of Technology, and Project Manager with Fraunhofer IAPT. You are one of the speakers at the Additive Intelligence 4.0 conference.

The theme of your session is “Novel strategies to enhance the productivity and robustness in additive manufacturing”. How will you approach this topic?

“I will talk about beam shaping, or the use of different beam profiles, in the Laser Powder Bed Fusion process, and highlight its impact on the robustness of the process, as well as on productivity and quality.”

What makes Powder Bed Fusion an essential technique to spotlight in this session?

“Powder Bed Fusion is the most widely used additive manufacturing (AM) process nowadays, accounting for over 90 % of all sold metal AM machines. This widespread adoption underscores its significance across various industries, and the core aspects of productivity and quality, is a crucial consideration for all sectors employing the powder bed fusion process."

Do you think that additive manufacturing is the future direction for both the manufacturing industry and the maintenance industry?

"Of course! I would say that additive manufacturing is an enabler for producing lighter and more functional parts, addressing sustainability concerns in the process. The attainment of these objectives relies on the design freedom offered by additive manufacturing. However, its use should be purpose-driven. Additive manufacturing tends to be more expensive, so your part needs to be better. Consequently, part redesign often becomes imperative to fully harness the benefits of additive manufacturing and transform it into an improved product. Given the higher costs involved, productivity gains are often sought to enhance overall cost efficiency.

Regarding maintenance, the powder bed fusion process is frequently highlighted as a viable option for producing spare parts. The ability to manufacture small lot sizes on demand, including lots as small as one unit, makes it particularly advantageous in this context. This is the area where its utility is most pronounced."

What are your thoughts and expectations on the conference?

"I really look forward to connecting with people from both industry and academia with a shared interest in advancing additive manufacturing. I am also genuinely excited about the opportunity to strengthen the collaboration with RISE during the event."

In a few words, what would you like to convey to your audience with your presentation?

"The key message is that the latest advancements in Laser Powder Bed Fusion have the potential to boost both the productivity and robustness of the process. This may open new fields of application that were previously deemed too cost-sensitive or impacted by various challenges."

Hello, Sebastian Piegert, Head of AM Technology at Siemens Energy. You are one of the speakers at the Additive Intelligence 4.0 conference.

The theme of your session is future trends and challenges in additive manufacturing. How will you approach this topic?

“My talk will offer insights into the progress of additive manufacturing at an industry level. I will dive into the challenges, highlighting areas where collaborative efforts between industry and academia are crucial for developing new solutions. Additionally, I will share examples of successful applications of additive manufacturing, showcasing some of the possibilities this technology has to offer, and hopefully sparking some new ideas. Finally, I will outline my perspective on the industry's direction and the necessary next steps.”

In short, what trends and challenges do you see ahead?

“Maybe it's not a trend, but a necessity. For additive manufacturing to survive as a viable manufacturing technology, it must transition into serial production of parts. In the current market, we observe a gradual increase in serial production, however not to the extent we would like. The aerospace sector, in particular, faces considerable regulatory challenges in meeting stringent quality requirements and managing costs at the same time. Within the area of industrial gas turbines, I would say that the prevalence of AM applications is growing. From a general perspective, there is an overarching trend towards digitalization. Furthermore, there is an evident shift from producing small bits and pieces to larger parts through additive manufacturing, regardless of technology.”

In what ways do you think that AM can benefit the future industry?

I can only reflect in detail on the benefits we experience at Siemens Energy. For us, additive manufacturing, along with its potential for innovative geometries, has provided solutions in critical areas such as emissions reduction, fuel flexibility, and enhanced efficiency. Additive manufacturing also plays a crucial role in addressing supply chain challenges, particularly in the realm of servicing products, when casting vendors or conventional manufacturers are unwilling or unable to support low-quantity production. It enables quick supply of spare parts, minimizing downtime.

Moreover, we have developed a couple of solutions where additive manufacturing is used not only for repairing but rather for upgrading components. This approach allows us to manufacture components that not only restore parts to customers' engines but also present enhanced versions, potentially with extended durability or improved performance. Aspects such as weight reduction, shape optimization, and aerodynamics, are of course relevant across diverse industries.

What are your thoughts, and expectations on the conference?

“I hope to connect with people facing similar challenges. Networking holds significant importance for me. Throughout the conference, I aim to gain insights into the different challenges perceived by various industry players and their approaches to applying different technologies. Additionally, I hope to explore possibilities for future collaborations, both within the industry and between industry and academia. An area in which, I would say, this conference is especially beneficial.”